review of us air force parts, materials and …the pmp issue impact of acquisition reform •...

© The Aerospace Corporation 2009


Review of US Air Force Parts, Materials and Processes (PMP)

Requirements

Larry HarzstarkDr. Steven Robertson

The Aerospace Corporation(310) 336-5883

10-16-09


Topics of Discussion

• Introduction• Unique Requirements for Space PMP• The PMP Issue - Impact of Acquisition Reform• The Way it Was: Prior to Acquisition Reform• The Way It Is: PMP Issues Today• Program Objectives to Reverse PMP Trends• Government Flow down• Summary of 5235A Requirements• Summary of 5236A Requirements


Introduction

• This presentation will provide an overview of how the US Air Force views Parts, Materials and Processes for space applications and the requirements it imposes on contractors building hardware


PMP for Space Is Unique


Space PMP Requirements


Unique Requirements for Space PMP

• Cannot repair or service during mission operation– Requires long mission life, high quality, high reliability, very high MTTF,

derating of application operational conditions• Radiation hardness (or tolerance) required, both total dose and single

event effects• Spacecraft charging• Contamination control

– Within parts to improve reliability– Outgassing requirements to prevent contamination of sensitive surfaces

• Operates in vacuum– Can cause thermal dissipation/stress issues

• Possible High shock, temperature cycling and temperature extremes• Degradation from aging• Atomic oxygen and micrometeoroids• Obsolescence management

Unique space environments and requirements shape PMP designs, screening and qualification practices


The PMP IssueImpact of Acquisition Reform

• Acquisition trends believed to have contributed to erosion of parts, materials and processes (PMP) practices

1980Space Level Parts

1990AcquisitionReform

2000 2005

Risk

PMPPractices

SystemComplexity

To Reverse PMP Space System Trends

1970MIL Level Parts

PMP Revitalization Goal:Reverse Practices and Risk Trends

Future


The Way it Was:Prior to Acquisition Reform

• Rigorous PMP specs & standards contractually implemented– Parts Selection and baseline quality levels (mandatory use of space

level parts)– Right of government approval– Parts derating– PMP Control Board (PMPCB) management– Verification/validation of part compliance to requirements– Destructive Physical Analysis (DPA) of all parts– Subcontractor oversight and requirements flow down

• Requirements for participation in GIDEP (Government Industry Data Exchange Program)

• Deliveries of PMP plans, lists, failures, etc.• Commercial off-the-shelf components not allowed – Extensive review

processes for any usage• Contractors well staffed with experienced component engineers

Rigorous requirements & practices provided good framework & visibility for PMP management


The Way It Is:PMP Issues Today

• Space parts industry has little clout with part suppliers• Space lines moved off-shore, becoming more difficult to monitor• Test elimination due to increased part complexity and optimization• Reduced requirements flow down and oversight across the board due

to resources and priorities• Deficiencies in new technology insertion practices• Reduced PMP requirements, staffing/resources and PMP practices

– Limited space qualification & requirements validation practices– Limited use of PMPCBs– Limited DPA

• Increased outsourcing and reduced technical expertise• Limited data sharing

Erosion in Practices & Increased Risk of PMP Failures


Program Objectives to Reverse PMP Trends

• Reverse PMP space acquisition trends through comprehensive strategic PMP Program management– Strong PMP engineering, management

processes and oversight across National Security Space

– Rigorous PMP processes– Strong cross program communication – Implementing practices that increase

likelihood problems will be prevented or discovered early and their proliferation and impact minimized


Government Flow down

• The government will flow down PMP requirements as part of the contract– Currently use the Aerospace PMP Technical Operating

Reports (TOR)• The government will have access and

knowledge of how the prime contractor implements the PMP program

• The prime contractor will review the requirements and flow down the applicable requirements to the subcontractors

• The prime contractor will monitor the PMP compliance by the subcontractors


Summary of 5235A Requirements

• TOR 2008-8583-5235A is the PMP Management requirements

• Forward – Use of non-government standards requires contractor

to ensure review of changes– Requirements for non repairable satellites, experimental

missions, and launch vehicles are the same – May be tailored, especially for experimental missions– As applicable when referenced in the contract

• References and ties back to technical requirements TOR 2008-8583-5236A

• Definitions – modified and added clarification (i.e., COTS, manufacturing baseline, New PMP Technology, etc)


Summary of 5235A Requirements• PMP Overall Program – requires a plan to

define how PMP program will be implemented• Existing Design or re-procurement of existing

design – Previously performed reliability and worst-case

analyses may be used to satisfy the requirements for re-procurement of existing designs except in cases where new parts are used to replace obsolete ones

• New Technology Requirements– Appendix D with detailed information on what is

necessary for insertion • PMPCB

– Government retains the right of review and disapproval of PMPCB decisions while present or within a mutually agreeable period



• Delegation of PMPCB meetings– Requirements to allow delegation for subcontractor

PMPCB meetings• PMPCB Responsibilities

– Activities PMPCB is responsible for– Data reviews– Parts, Materials and Processes Selection List– Part and Material Request approvals– Derating– DPA reviews– Etc

• Requirements Flow down– Appropriate flow down of requirements to

subcontractors



• PMP Selection Process– Space Quality Baseline– Requirement for Part and Material Request approval

on each item • PMP Procurement

– Order of precedence requirement; space baseline or SCD to the space requirements document

• PMP Characterization and Evaluation– Characterize parts and determine applicable

qualification requirements• Parts Derating Criteria

– Use of 5236A criteria or contractor criteria that is technically justified to PMPCB

– COTS treated as new technology



• PMP Drawing Review– Sign-off of drawings by applicable PMP representative

• PMP Prohibited and Restricted Usage– Pure tin >97% tin– Lead free solders– Emphasis on prohibited materials

• Plastic Encapsulated Microcircuits (PEMs) Usage– Requirements to allow usage of PEMs

• PMP Subcontract Management– Enhanced subcontractor monitoring


Summary of 5235A Requirements• PMP Qual

– Defines requirement for all PMP to be qualified• Qual by Similarity

– Defines conditions upon which similarity/extension maybe utilized• Authorized Sources of Supply

– Added language to buy from OEM or franchised distributor to reduce counterfeit risk

• Customer Source Inspection– Defines conditions for what inspection should be performed by source when

applicable • Traceability

– Defines requirement for electronic, mechanical and material traceability• Incoming Inspection

– DPA– Compositional Analysis

• PMP Defective Material Control– Defines the system and control of defective PMP

• Re-use of Parts and Materials– Defines the conditions and approval process for the re-use of parts and

materials• Failure Analysis

– Defines the conditions when failure analysis should be performed



• Handling & Storage– Defines the controls for handling and storage of PMP

• Electro-Static Discharge (ESD)– Defines that parts sensitive to ESD must be controlled

and handled in accordance with established procedures

• DPA– DPA for all parts including mil-spec parts– Maintain (& provide if requested) electronic copies of

DPA reports• Shelf Life Control

– Parts shelf life control requirements enhanced• GIDEP

– Defines the participation in the GIDEP program and the responsibilities



• PMP Corrosion Control– Ensure all materials are evaluated and controlled

• Contamination Control Program– Material outgassing

• PMP Radiation Hardness Control– Defines the hardness assurance

requirement/methodology• Government Furnished Equipment (GFE)

– Requirements for handling and control of GFE• SPWG

– Support to annual Space Parts Working Group Meeting



• PMP Selection List– Approved list to select PMP

• PMP As Designed List– List defining PMP designed into system

• Added PMP As Built List Requirement– List defines actual PMP used in hardware

• Space Quality Baseline – Defines approved space level PMP not requiring

additional approvals


Summary of 5236A Requirements• TOR 2008-8583-5236A is the PMP Technical

requirements• Definitions

– Clarified definitions of nominal and worst case• Derating

– Defines derating which enhances reliability• New Technology

– Defines requirement for new technology insertion• In-process Controls

– Defined the requirements for various in-process controls which are part type dependent

• Screening– Defines 100% testing to weed out marginal parts

• Qualification– Defines requirements for PMP qualification

• Quality Conformance Inspection – Defines lot acceptance criteria

• Qualification by Extension– Defines conditions upon which similarity maybe utilized



• Detailed Requirements– Each commodity type has own section detailing

– Screening– Qualification– Quality Conformance Inspection– Design and Construction– Reliability– Radiation – Process Controls– Prohibited Materials

– Enhanced hybrid element evaluation and requalification requirements

– Working on enhancing MIL-PRF-38534 to be in agreement– Added RF/microwave, surface acoustical wave and photonics

device sections– Changes to Printed Wiring Board sections– Resistor and capacitor sections modified to correct some

procurement issues observed by contractors


Summary

• Space requirements for PMP are unique• Prior to acquisition reform, rigorous

requirements & practices provided good framework & visibility for PMP management

• Post acquisition reform, stringent PMP practices and requirements have eroded

• Aerospace PMP TORs have been generated and implemented on US Air Force contracts to enhance the PMP requirements and reduce the associated risks

review of us air force parts, materials and …the pmp issue impact of acquisition reform •...

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